3 Things to Know About Fixing a Roto-Molded Cooler

Plastic weld the shell, don’t use epoxy Epoxy or JB Weld won’t flex with the plastic and will fail under temperature changes or a heavy load. Plastic welding bonds the material back together and lasts.

Use zip ties as filler rod for the weld Get a soldering iron or plastic welder. Melt the crack edges and fill with melted zip tie material—it’s the same polyethylene. The result is ugly but strong.

Replace the handle instead of repairing it Handle hinge points take constant weight and movement. Even a good plastic weld will fatigue and snap again. Just drill out the old handle and install a new one.